Multiple heater exhaust aftertreatment system architecture and methods of control thereof

Abstract

A system includes a first heater positioned in or proximate to an exhaust aftertreatment system in exhaust gas-receiving communication with an engine, a second heater positioned downstream of the first heater, and a controller coupled to the first and second heaters. The controller is structured to: determine, based on information indicative of a temperature regarding the exhaust aftertreatment system, that the temperature regarding the exhaust aftertreatment system is below a predefined temperature threshold; determine that the second heater is in or likely in an error state; and control a temperature regarding the exhaust aftertreatment system using the first heater in response to determining that the second heater is in or likely in the error state, wherein the first heater controls the temperature regarding the exhaust aftertreatment system after a temperature regarding an engine intake air is at or above a predefined air intake temperature threshold.

What is claimed is: 
     
       1. A system, comprising:
 a first heater positioned in or proximate to an air intake of an engine; 
 a second heater positioned in exhaust gas-receiving communication with the engine; and 
 a controller coupled to the first and second heaters, the controller structured to:
 determine, based on information indicative of a temperature regarding the exhaust aftertreatment system, that the temperature regarding the exhaust aftertreatment system is below a predefined temperature threshold; 
 determine that the second heater is in or likely in an error state; and 
 control a temperature regarding the exhaust aftertreatment system using the first heater in response to determining that the second heater is in or likely in the error state, wherein the first heater controls the temperature regarding the exhaust aftertreatment system after a temperature regarding an engine intake air is at or above a predefined air intake temperature threshold. 
 
 
     
     
       2. The system of  claim 1 , wherein the controller is further structured to:
 receive information indicative of a characteristic of a battery coupled to the first heater and the second heater; 
 control a temperature regarding the exhaust aftertreatment system without using the first heater or the second heater in response to determining that the characteristic of the battery is below a predefined threshold; and 
 control a temperature regarding the exhaust aftertreatment system using one of the first heater and the second heater in response to determining that the characteristic of the battery is above the predefined threshold but below a second predefined threshold. 
 
     
     
       3. The system of  claim 2 , wherein the controller is structured to modulate an amount of heat provided by one of the first heater and the second heater based on the characteristic of the battery. 
     
     
       4. The system of  claim 3 , wherein the characteristic of the battery is at least one of a state of charge (SOC), a state of health (SOH), and a voltage. 
     
     
       5. The system of  claim 1 , wherein controlling the temperature regarding the exhaust aftertreatment system without using the first heater or the second heater includes one or more of changing an engine operating condition, initiating an engine cylinder deactivation mode, causing a hydrocarbon dosing, causing a post-fuel injection, or a manipulation of charge air. 
     
     
       6. The system of  claim 1 , wherein the information indicative of the temperature regarding the exhaust aftertreatment system is at least one of a temperature of exhaust gas flowing through the exhaust aftertreatment system or a temperature of a component or components of the exhaust aftertreatment system. 
     
     
       7. The system of  claim 1 , wherein the controller is further structured to:
 determine a heating time based on the information indicative of the temperature regarding the exhaust aftertreatment system; and 
 control the temperature regarding the exhaust aftertreatment system for the heating time. 
 
     
     
       8. The system of  claim 1 , wherein the controller is further structured to:
 receive one or more fault codes regarding the second heater; and 
 determine that the second heater is in or likely in an error state based on the one or more fault codes. 
 
     
     
       9. The system of  claim 1 , wherein the controller is further structured to:
 receive set of temperature values regarding a temperature of the exhaust aftertreatment system downstream of the second heater; and 
 determine that the second heater is in or likely in an error state based on the set of temperature values indicating that the temperature of the exhaust aftertreatment system downstream of the second heater is not increasing. 
 
     
     
       10. The system of  claim 1 , wherein the controller is further structured to:
 receive at least one of a voltage value regarding the second heater or current value regarding the second heater; and 
 determine that the second heater is in or likely in an error state based on at least one of the voltage value or the current value being at or below a predetermined threshold. 
 
     
     
       11. A system, comprising:
 a first heater positioned in or proximate to an air intake of an engine; 
 a second heater positioned in exhaust gas-receiving communication with the engine; and 
 a controller coupled to the first and second heaters, the controller structured to:
 determine that the engine is undergoing a cold start; 
 determine a characteristic of a battery based on receiving information indicative of the characteristic of the battery; 
 cause a temperature of the exhaust gas to increase without using the first heater or the second heater responsive to determining that the characteristic of the battery is below a predefined threshold and that the engine is undergoing the cold start; 
 activate the first heater responsive to determining that the characteristic of the battery is above the predefined threshold; 
 receive information indicative of a temperature of an exhaust aftertreatment system; 
 determine that the second heater is in or likely in an error state responsive to determining that the temperature of the exhaust aftertreatment system is at or below a predefined aftertreatment temperature threshold; and 
 disable the first heater responsive to determining that the temperature of the exhaust aftertreatment system is above the predefined aftertreatment temperature threshold. 
 
 
     
     
       12. The system of  claim 11 , wherein causing the temperature of the exhaust gas to increase comprises at least one of changing an engine operating condition, causing an introduction of hydrocarbons into the exhaust gas, causing a post-fuel injection, or a manipulation of charge air to increase the temperature of the exhaust gas. 
     
     
       13. The system of  claim 11 , wherein causing the temperature of the exhaust gas to increase comprises a manipulation of charge air including bypassing a charge air cooler when directing the charge air into the engine. 
     
     
       14. The system of  claim 11 , wherein causing the temperature of the exhaust gas to increase comprises at least one of increasing a load on the engine, increasing a speed of the engine, or deactivating one or more cylinders of the engine. 
     
     
       15. A system, comprising:
 an intake heater positioned in or proximate to an air intake of an engine; 
 a first aftertreatment system heater positioned in exhaust gas-receiving communication with the engine; 
 a second aftertreatment system heater positioned in exhaust gas-receiving communication with the engine and downstream of the first heater; and 
 a controller coupled to the intake heater, the first heater, and the second heater, the controller structured to:
 operate the intake heater to heat air entering the engine; 
 determine, based on information indicative of a temperature of an exhaust aftertreatment system, that the temperature indicative of the exhaust aftertreatment system is below a predefined temperature threshold; and 
 responsive to determining that at least one of the first aftertreatment system heater or the second aftertreatment system heater is in or likely in an error state, control the temperature indicative of the exhaust aftertreatment system using the intake heater. 
 
 
     
     
       16. The system of  claim 15 , wherein the controller is further structured to:
 determine a characteristic of a battery based on receiving information indicative of the characteristic of the battery; and 
 cause a temperature of exhaust gas from the engine to increase without using the intake heater, the first aftertreatment system heater, or the second aftertreatment system heater responsive to determining that the characteristic of the battery is below a predefined threshold and that the engine is undergoing the cold start. 
 
     
     
       17. The system of  claim 15 , wherein the controller is further structured to:
 determine a characteristic of a battery based on receiving information indicative of the characteristic of the battery prior to operating the intake heater; and 
 operate the intake heater to heat air entering the engine responsive to determining that the characteristic of the battery is above the predefined threshold. 
 
     
     
       18. The system of  claim 15 , wherein the controller is further structured to disable the intake heater after a predefined period of time and responsive to determining that that at least one of the first aftertreatment system heater or the second aftertreatment system heater is not in or likely not in the error state. 
     
     
       19. The system of  claim 18 , wherein the controller is further structured to operate at least one of the first aftertreatment system heater or the second aftertreatment system heater after the predefined period of time and responsive to determining that that at least one of the first aftertreatment system heater or the second aftertreatment system heater is not in or likely not in the error state.